Novel Design of an Integrated Pulp Mill Biorefinery for the ...

More documents

Recommendations

Info

List of Tables Table 1: Bleaching chemicals for ECF and TCF bleaching processes. ........................................ 14 Table 2: Syngas composition from gasification with various gasifying agents. ........................... 16 Table 3: Average syngas composition from Shell and Texaco entrained flow gasifiers .............. 21 Table 4: Comparison of dimethyl ether’s physical and thermo-physical properties to commonly used fuels. ..................................................................................................................................... 21 Table 5: Cost scale of Fischer-Tropsch catalyst in 2001 .............................................................. 32 Table 6: Contaminant specification for cobalt FT synthesis, and cleaning effectiveness of wet and dry gas cleaning ...................................................................................................................... 34 Table 8: Hydrocarbons and associated names .............................................................................. 37 Table 9: White liquor composition. .............................................................................................. 40 Table 10: Green liquor composition. ............................................................................................ 40 Table 11: Chemical compound addition. ...................................................................................... 41 Table 12: Steam Demand Pulp Mill.............................................................................................. 41 Table 13: Energy produced by KAM2 boiler. .............................................................................. 42 Table 14: Energy produced by KAM2 boiler. .............................................................................. 42 Table 15: Daily Electricity Demand. ............................................................................................ 43 Table 16: Daily Steam Demand. ................................................................................................... 43 Table 17: General operating parameters for Texaco Gasifier. ...................................................... 45 Table 18: Properties and composition of kraft black liquor. ........................................................ 46 Table 19: Coal analysis of Pittsburgh No. 8 bituminous coal sample. ......................................... 46 Table 20: Ash analysis of Pittsburgh No. 8 bituminous coal sample ........................................... 47 Table 21: Mass balance for coal-black liquor gasifier feed. ......................................................... 47 Table 22: Performance of coal-black liquor gasification. ............................................................. 48 Table 23: Experimental syngas composition and estimated syngas stream. ................................ 49 Table 24: Syngas Calorific Value. ................................................................................................ 49 Table 25: Solid and liquid phases predicted by FactSage modeling package. ............................. 50 Table 26: Fuel mass requirements for gasification feed. .............................................................. 51 Table 27: The composition and components of the raw syngas. .................................................. 52 Table 28: FT-diesel fuel synthesis parameters used in FT-diesel production design. .................. 57 Table 29: Quality requirements for gas turbine fuel gas. .............................................................. 64 Table 30: Power from Syngas cooled steam. ................................................................................ 64 Table 31: Power from F-T diesel synthesis waist steam. .............................................................. 64 Table 32: The recovered energy from HRSG exhaust gas to saturate H2O in the Water Heater. 65 Table 33: Power generated in the steam turbine with energy recovered from HRSG. ................. 65 Table 34: Main operating parameters of power and heat generation. ........................................... 66 Table 35: Heat and power generation in the design. ..................................................................... 66 Table 36: Energy and efficiency summary of DME design and FTD design. .............................. 67 6
1 Introduction The global transport sector uses approximately 70 to 90 EJ of energy per year[1]. In OECD countries, 97% of the transport sector uses petroleum-based fuels. It is estimated that the world has peaked in petroleum production, and world petroleum consumption has outpaced newfound reserves. Therefore, great efforts in research and development have been made into new vehicle technology and new fuels. A means of reducing or eliminating the dependency on petroleum is the use fuels derived from natural gas, biomass or coal. For this reason, methanol, ethanol, dimethyl ether, Fischer-Tropsch fuels, biodiesel, etc. are being researched as alternative fuels. Whatever fuel is to supplement or replace petroleum, it must address the following criteria: availability, economics, acceptability, environmental and emissions, national security, technology, and versatility[2]. This report details a gasification-based production scheme to produce dimethyl ether and Fischer-Tropsch fuels as alternative fuels that could potentially replace petroleum-based fuels in terms of the availability, environmental and emissions factors, and technology. Attention is growing in research areas where alternative fuels are produced from biomass feedstocks based on the potential for CO2 reduction and energy security. Fischer-Tropsch Diesel (FTD) is a promising fuel that can be produced from gasified hydrocarbons, such as coal, natural gas and biomass feed stocks. FTD is a high quality diesel fuel that can be used at 100% concentration or blended with lower quality petroleum based fuel to improve performance [3]. The main advantage of large scale production of FTD is that no changes or modifications are necessary to utilize it in current fill stations or vehicles. With social, political and environmental demands for eco-friendly renewable transportation fuel, FTD produced from biomass should be considered. FTD does not have the logistical problems of bio-diesel. FTD does not need to be blended with regular diesel fuel. It can be run at a 100% concentration without vehicle modifications. FTD does not suffer from cold flow problems like bio-diesel[3]. Fischer-Tropsch synthesis (FTS) is a mature technology that has been commercially utilized to produce FTD by Sasol since 1955. Company such as Shell, Chevron, ExxonMobil and Rentech have been creating production facilities as FTD has become more economically feasible with the onset of high petroleum fuel costs. Production efficiency of FTD is lost to low selectivity of hydrocarbon chains during Fischer-Tropsch synthesis. When creating FTD, middle distillates and long chained wax are desired, but regardless naphtha and light carbon chain gases are produced. Ekbom et al. created models showing Fischer-Tropsch products having a 65% biomass-to-fuel efficiency, with 43% being FTD and 22% being naphtha [4]. In a compellation of previous works, Semelsberger et al. reported FTD to have a ~59% well-to-tank efficiency, based on syngas produced by natural gas[5]. Production of FTD from coal can be assumed to have similar trends in production efficiency since FTD synthesis begins with gasification of a feed stock to create syngas. U.S. pulp and paper mills have an opportunity to utilize biomass (as black liquor) and coal gasification technologies to improve the industry’s economic and energy efficiency performance with new value-added streams including liquid transportation fuels from synthesis gas. The black liquor pulping byproduct contains cooking chemicals and calorific energy that should be optimally recovered through gasification. Although the heating value per ton of dried black liquor solids is relatively low, the average Kraft mill represents an energy source of 250-500 MW [1,2]. Black liquor is 7
Page 1 and 2: Novel Design of an Integrated Pulp
Page 3 and 4: Table of Contents List of Figures .
Page 5: List of Figures Figure 1: Price of
Page 9 and 10: 2 Background 2.1 Pulp Mill Backgrou
Page 11 and 12: 2.1.2.2 Chemical Pulping The most c
Page 13 and 14: sodium sulfide and sodium carbonate
Page 15 and 16: process described in the section on
Page 17 and 18: 2.2.1 Low-Temperature Black Liquor
Page 19 and 20: Figure 2: Chemrec gasification proc
Page 21 and 22: Table 3: Average syngas composition
Page 23 and 24: DME than that could be obtained fro
Page 25 and 26: U.S. Patent[58] and European Patent
Page 27 and 28: Figure 4: Topsøe gas phase technol
Page 29 and 30: DME Workshop, Japan (Sept. 7, 2000)
Page 31 and 32: 2.4.1. Fischer-Tropsch Reactors The
Page 33 and 34: kpH 2 pCO Cobalt rate = 2 (2.4.1) (
Page 35 and 36: invention of Fischer-Tropsch in the
Page 37 and 38: Table 7: hydrocarbons and associate
Page 39 and 40: 3 Process Design 3.1 Pulp Mill 3.1.
Page 41 and 42: carbonate is fired in a lime kiln t
Page 43 and 44: lost and the pulp that provides tha
Page 45 and 46: Table 16: General operating paramet
Page 47 and 48: Table 19: Ash analysis of Pittsburg
Page 49 and 50: Table 22: Experimental syngas compo
Page 51 and 52: 3.2.5 Process Options and Flexibili
Page 53 and 54: Nitrogen compounds Nitrogen from th
Page 55 and 56: 3.3.2.3 Reactors A single-step gas
Page 57 and 58:
Table 27: FT-diesel fuel synthesis
Page 59 and 60:
3.5.2 Power Generation Process Desi
Page 61 and 62:
Figure 21: Schematic of biorefinery
Page 63 and 64:
ar) reacts with the fuel in the com
Page 65 and 66:
Figure 25showed the detailed energy
Page 67 and 68:
4. Design Summary The DME design an
Page 69 and 70:
Figure 27: Mass and energy flow of
Page 71 and 72:
References 1. Åhman, M., G. Modig,
Page 73 and 74:
42. R.A. Peascoe, J.R.K., C.R. Hubb
Page 75 and 76:
PerformanceSimulation. 2006, Prince
Page 77 and 78:
Appendix Appendix A MP Steam Demand
Page 79 and 80:
Appendix B: Composite Fuel Blend to
Page 81 and 82:
DME Density = 0.67 kg/L (at 20 °C)
Page 83 and 84:
Air Separation Unit Requirements Ba
Page 85 and 86:
Purge gas: CO conversion is 60%, 40
Page 87 and 88:
Appendix D: FTD Synthesis Two diffe
Page 89 and 90:
Table D.3: The hydrocarbon product
Page 91 and 92:
Figure D.3 Mass and energy balance
Page 93 and 94:
Table D.3 Mass and energy balance o
Page 95 and 96:
Appendix E: Heat and Power Generati
Page 97 and 98:
Energy H2O absorbed MW 46.71 Using
Page 99 and 100:
Combustion 2CO+O2→ 2CO2 + 566 kJ/
Page 101 and 102:
Specific Heat (cp) b kJ/kgK 1.072 E
Page 103 and 104:
Specific Heat of Steam (cp) kJ/kgK
Page 105:
Appendix F: Concept Map 105
show all

Novel Design of an Integrated Pulp Mill Biorefinery for the ...

Create successful ePaper yourself

Delete template?

Save as template?